Clinching joints with an additional deformable rivet are modifications of the clinching joints. T... more Clinching joints with an additional deformable rivet are modifications of the clinching joints. The clinch riveting (CR) joint is formed indirectly by a deformable rivet. The research included an analysis of CR joints’ forming process for aluminum alloy sheets made of AW 6082 in T6 state condition and AW 5754 in three different state conditions: H11, H22 and H24. As a result of forming the joint for various sheet arrangements, the highest value of blocking the upper sheet in the lower sheet (tu) was obtained for the arrangements with two 5754-H24 aluminum alloy sheets. For such a large interlock parameter tu, the greatest thinning of lower sheet (tn) was obtained, which influenced the maximum tensile shear force and the joint failure mechanism. Based on the load-displacement diagrams obtained from the static shear test of lap joints, the total energy of failure and energy to achieve the maximum load capacity were calculated. The highest energy absorption to achieve the maximum load ...
Łączenie przetloczeniowe blach grubszych niz 1 mm nie sprawia klopotow i jest coraz chetniej stos... more Łączenie przetloczeniowe blach grubszych niz 1 mm nie sprawia klopotow i jest coraz chetniej stosowane w procesach montazowych konstrukcji blaszanych. Zalety takiego spajania materialow sprawily, ze jest obecnie coraz cześciej wykorzystywane w procesach produkcyjnych (rys. 1). Prostota wykonania, a przede wszystkim obnizenie kosztow produkcji gotowego wyrobu poprzez wyeliminowanie kosztow dodatkowego lącznika czyni je najbardziej rozpowszechnionymi wśrod rodziny polączen przetloczeniowych. W przypadku materialow dających sie obrabiac przez plastyczne formowanie polączenie odbywa sie przez proces miejscowego wytlaczania lączonych blach zazwyczaj na zimno przy uzyciu stempla i matrycy o odpowiedniej geometrii. Zalety tej metody doprowadzily do opracowania na podstawie przetlaczania wielu innych jej odmian [1]. Najbardziej rozpowszechnione na polskim rynku są systemy montazu firmy TOX Pressotechnik. Materialy trudno obrabialne, np. stopy magnezu, mogą byc uprzednio wstepnie miejscowo p...
Presented was the results of experimental analysis of single riveted joints strength. The joints ... more Presented was the results of experimental analysis of single riveted joints strength. The joints shear strength was determined in temperature of 23, 400, 600, 800 Celsius degrees. The obtained results helped to explain how the temperature affects on the joint load characteristic. The experimental research was carried out for zinc coated S350GD sheet metal material.
The Archives of Automotive Engineering – Archiwum Motoryzacji
W publikacji przedstawiono technologię łączenia blach za pomocą przetłaczania (ang. clinching). C... more W publikacji przedstawiono technologię łączenia blach za pomocą przetłaczania (ang. clinching). Clinching to proces scalania warstw materiału z udziałem odkształceń plastycznych. Przedstawiono przebieg procesu formowania złącza w klasycznej odmianie kształtowania. Scharakteryzowano fazy formowania przetłoczenia w trakcie łączenia blach. Opisano metody oceny jakości wykonania złączy, a także przykłady ich zastosowania. Obecnie istnieją różne konstrukcje używanych narzędzi, do formowania tego typu złączy. Najczęściej stosowanymi narzędziami są stempel, oraz matryca okrągła i niedzielona o zarysie osiowo-symetrycznym. Inne odmiany konstrukcji matryc pozwalają na znaczne obniżenie siły kształtowania złącza. W pracy zwrócono uwagę na rożną konstrukcję możliwych do zastosowania matryc, możliwość łączenia nie tylko materiałów metalicznych ale także kombinacji metalicznych z kompozytowymi. Opisano możliwości tworzenia złączy hybrydowych tj. klejowo-przetłaczanych. Ponadto scharakteryzowano ...
Continuous development in aerospace industry puts increasingly higher challenges for manufacturer... more Continuous development in aerospace industry puts increasingly higher challenges for manufacturers of aerospace parts. The production process of aerospace parts must meet strict requirements. One of them is inspection of part's dimensions at the various stages of its production. It is important to proceed with the measurements when the part reaches desired temperature (usually 20°C). Temperature of the parts after machining process may be raised to approx. 60°C, hence they need to be cooled down. Cooling requires especially long time in case of large volume parts, which leads to prolongation of their delivery time. The research and development work in this field is therefore focused mainly on developing new solutions which may accelerate the cooling process. The present study describes the influence of temperature of workpiece on the result of dimensions measurement and a new design of refrigerator developed and patented by WALDREX Sp. z o.o. Refrigerator is equipped with an ins...
Advances in Manufacturing Science and Technology, 2016
In the paper an analysis of the result obtained in numerical simulation of tools load during Al M... more In the paper an analysis of the result obtained in numerical simulation of tools load during Al Mg 4.5Mn0.7 aluminium alloy sheets joining by SPR process. Numerical simulations of joining process were made, with use finite element method (FEM), in MSC.Marc 2010 commercial program. Experimental research of SPR joining process was made on test stand: press with electric drive and special tools. High precision of joint cross-sections from experimental and numerical research was obtained. It was observed that the surface pressure on the punch face depend on the rivet deformation and they are changing it non-linear way. The stress distribution change along line on the rivet head surface, through its center, is determined by the recess size of the tubular part of the rivet in the joined sheets. The results of numerical simulation can be used in developing process of SPR tools with shape modification.
This paper presents the results of experimental researches on effect of clinching joint’s load di... more This paper presents the results of experimental researches on effect of clinching joint’s load direction change on its characteristics and the maximum shearing force value. The single-folded clinching joints made of aluminum sheet AW1050A have been the subject of researches. Properly prepared specimens of rectangle clinching joints with material notch have been shear tested on the tensile testing machine UTS 100. The extreme joint destruction have been analyzed for the layout angle β = 0°, 90°. The separation mechanism has been described for all angle values β = 0o, 30o, 45o, 90o. The total separation work by joint shearing has also been mentioned.
The article presents the analysis of the structure of the load capacity of riveted joints. For th... more The article presents the analysis of the structure of the load capacity of riveted joints. For the four joining systems the lap joint specimens were made and tested in the shearing test. The joints were prepared for the three combinations of the DC01 steel and EN AW- 5754 aluminium alloy sheets with the thickness of 2mm. On the basis of the obtained load-elongation diagram tensile shear test curves, the basic parameters defined in the ISO/DIS 12996 standard were determined. In the case of the conventional riveted joints the maximum load capacity of the joint is determined by the strength of the fastener. For the joints with aluminium-steel blind rivet , the load capacity of the joint was on the strength limit of the rivet tubular part and on the strength limit of the sheet material. The strength of the SSPR joint is determined by the mechanical properties of the material of the joined sheets. From all sheets and rivet specimens arrangements the highest load capacity of the joint was...
In this thesis, the results of an experimental analysis of blanking angled hooks with a punch of ... more In this thesis, the results of an experimental analysis of blanking angled hooks with a punch of a sloping face in a thin steel sheet with a hardness of 55 HRC are presented. The blanking punch was made of K340 cold-work tool steel. Tests were carried out for three values of clearance, 5%, 10%, and 15% of sheet thickness. The results of the analysis of the influence of the number of cuts made by the punch on the growth of the burr at the sheet edge were presented. Moreover, the influences of the clearance on the initial values of burr (bh), deflection (Hb), and the bending radius (Rb) of the hook have been shown. The influence of the friction path on the intensity of degradation of working surfaces and the blanking edges of the punch was also demonstrated. The obtained results allow the selection of the proper clearance and new tool materials for blanking blades working in particularly difficult tribological conditions.
Clinching joints with an additional deformable rivet are modifications of the clinching joints. T... more Clinching joints with an additional deformable rivet are modifications of the clinching joints. The clinch riveting (CR) joint is formed indirectly by a deformable rivet. The research included an analysis of CR joints’ forming process for aluminum alloy sheets made of AW 6082 in T6 state condition and AW 5754 in three different state conditions: H11, H22 and H24. As a result of forming the joint for various sheet arrangements, the highest value of blocking the upper sheet in the lower sheet (tu) was obtained for the arrangements with two 5754-H24 aluminum alloy sheets. For such a large interlock parameter tu, the greatest thinning of lower sheet (tn) was obtained, which influenced the maximum tensile shear force and the joint failure mechanism. Based on the load-displacement diagrams obtained from the static shear test of lap joints, the total energy of failure and energy to achieve the maximum load capacity were calculated. The highest energy absorption to achieve the maximum load ...
Łączenie przetloczeniowe blach grubszych niz 1 mm nie sprawia klopotow i jest coraz chetniej stos... more Łączenie przetloczeniowe blach grubszych niz 1 mm nie sprawia klopotow i jest coraz chetniej stosowane w procesach montazowych konstrukcji blaszanych. Zalety takiego spajania materialow sprawily, ze jest obecnie coraz cześciej wykorzystywane w procesach produkcyjnych (rys. 1). Prostota wykonania, a przede wszystkim obnizenie kosztow produkcji gotowego wyrobu poprzez wyeliminowanie kosztow dodatkowego lącznika czyni je najbardziej rozpowszechnionymi wśrod rodziny polączen przetloczeniowych. W przypadku materialow dających sie obrabiac przez plastyczne formowanie polączenie odbywa sie przez proces miejscowego wytlaczania lączonych blach zazwyczaj na zimno przy uzyciu stempla i matrycy o odpowiedniej geometrii. Zalety tej metody doprowadzily do opracowania na podstawie przetlaczania wielu innych jej odmian [1]. Najbardziej rozpowszechnione na polskim rynku są systemy montazu firmy TOX Pressotechnik. Materialy trudno obrabialne, np. stopy magnezu, mogą byc uprzednio wstepnie miejscowo p...
Presented was the results of experimental analysis of single riveted joints strength. The joints ... more Presented was the results of experimental analysis of single riveted joints strength. The joints shear strength was determined in temperature of 23, 400, 600, 800 Celsius degrees. The obtained results helped to explain how the temperature affects on the joint load characteristic. The experimental research was carried out for zinc coated S350GD sheet metal material.
The Archives of Automotive Engineering – Archiwum Motoryzacji
W publikacji przedstawiono technologię łączenia blach za pomocą przetłaczania (ang. clinching). C... more W publikacji przedstawiono technologię łączenia blach za pomocą przetłaczania (ang. clinching). Clinching to proces scalania warstw materiału z udziałem odkształceń plastycznych. Przedstawiono przebieg procesu formowania złącza w klasycznej odmianie kształtowania. Scharakteryzowano fazy formowania przetłoczenia w trakcie łączenia blach. Opisano metody oceny jakości wykonania złączy, a także przykłady ich zastosowania. Obecnie istnieją różne konstrukcje używanych narzędzi, do formowania tego typu złączy. Najczęściej stosowanymi narzędziami są stempel, oraz matryca okrągła i niedzielona o zarysie osiowo-symetrycznym. Inne odmiany konstrukcji matryc pozwalają na znaczne obniżenie siły kształtowania złącza. W pracy zwrócono uwagę na rożną konstrukcję możliwych do zastosowania matryc, możliwość łączenia nie tylko materiałów metalicznych ale także kombinacji metalicznych z kompozytowymi. Opisano możliwości tworzenia złączy hybrydowych tj. klejowo-przetłaczanych. Ponadto scharakteryzowano ...
Continuous development in aerospace industry puts increasingly higher challenges for manufacturer... more Continuous development in aerospace industry puts increasingly higher challenges for manufacturers of aerospace parts. The production process of aerospace parts must meet strict requirements. One of them is inspection of part's dimensions at the various stages of its production. It is important to proceed with the measurements when the part reaches desired temperature (usually 20°C). Temperature of the parts after machining process may be raised to approx. 60°C, hence they need to be cooled down. Cooling requires especially long time in case of large volume parts, which leads to prolongation of their delivery time. The research and development work in this field is therefore focused mainly on developing new solutions which may accelerate the cooling process. The present study describes the influence of temperature of workpiece on the result of dimensions measurement and a new design of refrigerator developed and patented by WALDREX Sp. z o.o. Refrigerator is equipped with an ins...
Advances in Manufacturing Science and Technology, 2016
In the paper an analysis of the result obtained in numerical simulation of tools load during Al M... more In the paper an analysis of the result obtained in numerical simulation of tools load during Al Mg 4.5Mn0.7 aluminium alloy sheets joining by SPR process. Numerical simulations of joining process were made, with use finite element method (FEM), in MSC.Marc 2010 commercial program. Experimental research of SPR joining process was made on test stand: press with electric drive and special tools. High precision of joint cross-sections from experimental and numerical research was obtained. It was observed that the surface pressure on the punch face depend on the rivet deformation and they are changing it non-linear way. The stress distribution change along line on the rivet head surface, through its center, is determined by the recess size of the tubular part of the rivet in the joined sheets. The results of numerical simulation can be used in developing process of SPR tools with shape modification.
This paper presents the results of experimental researches on effect of clinching joint’s load di... more This paper presents the results of experimental researches on effect of clinching joint’s load direction change on its characteristics and the maximum shearing force value. The single-folded clinching joints made of aluminum sheet AW1050A have been the subject of researches. Properly prepared specimens of rectangle clinching joints with material notch have been shear tested on the tensile testing machine UTS 100. The extreme joint destruction have been analyzed for the layout angle β = 0°, 90°. The separation mechanism has been described for all angle values β = 0o, 30o, 45o, 90o. The total separation work by joint shearing has also been mentioned.
The article presents the analysis of the structure of the load capacity of riveted joints. For th... more The article presents the analysis of the structure of the load capacity of riveted joints. For the four joining systems the lap joint specimens were made and tested in the shearing test. The joints were prepared for the three combinations of the DC01 steel and EN AW- 5754 aluminium alloy sheets with the thickness of 2mm. On the basis of the obtained load-elongation diagram tensile shear test curves, the basic parameters defined in the ISO/DIS 12996 standard were determined. In the case of the conventional riveted joints the maximum load capacity of the joint is determined by the strength of the fastener. For the joints with aluminium-steel blind rivet , the load capacity of the joint was on the strength limit of the rivet tubular part and on the strength limit of the sheet material. The strength of the SSPR joint is determined by the mechanical properties of the material of the joined sheets. From all sheets and rivet specimens arrangements the highest load capacity of the joint was...
In this thesis, the results of an experimental analysis of blanking angled hooks with a punch of ... more In this thesis, the results of an experimental analysis of blanking angled hooks with a punch of a sloping face in a thin steel sheet with a hardness of 55 HRC are presented. The blanking punch was made of K340 cold-work tool steel. Tests were carried out for three values of clearance, 5%, 10%, and 15% of sheet thickness. The results of the analysis of the influence of the number of cuts made by the punch on the growth of the burr at the sheet edge were presented. Moreover, the influences of the clearance on the initial values of burr (bh), deflection (Hb), and the bending radius (Rb) of the hook have been shown. The influence of the friction path on the intensity of degradation of working surfaces and the blanking edges of the punch was also demonstrated. The obtained results allow the selection of the proper clearance and new tool materials for blanking blades working in particularly difficult tribological conditions.
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Papers by Jacek Mucha